Protective liner

ABSTRACT

The invention is directed to a device and method of protecting a bathtub or shower unit during the construction of a building. The device is a pre-molded polymer foam liner that is placed inside the bathtub or shower unit and that is then removed upon the completion of the construction. The liner can be easily adapted to match holes in the bathtub or shower unit as the case may be.

FIELD OF THE INVENTION

The present invention relates to a device and a method of protectingbathtubs and shower units, and in particular to protecting bathtubs andshower units during the construction of a building.

BACKGROUND

During the framing stage of construction of a building it is commonpractice to place bathtubs and shower units (collectively referred to as“bathing fixtures”) in the rooms that that they will eventually beinstalled in. Consequently, such bathing fixtures are exposed to asubstantial portion of the construction and finishing process. Duringconstruction, bathing fixtures are inadvertently subjected to a varietyof physical abuses including rain, dirty footwear, rocks, nails,staples, screws, ladders, stilts, trowels, knives, dropped tiles andgeneral use as a garbage receptacle. Such physical abuse frequentlydamages the exposed surfaces of the bathing fixtures manifesting itselfin the form of stains, scratches, dents and chips.

Various types of cover have been used to try and protect bathingfixtures during the construction process. Many of the covers that havebeen tried are makeshift in nature having little effect, or evencompounding the damage. Wooden and cardboard covers have been used butthey tend to slide around on the surface of the bathing fixtures causingscratches at the point of contact. Further, trades people frequentlydiscard such covers because the cover physically interferes with theirtasks such as tiling, framing and plumbing. Paper based covers are alsoof limited utility as they tend to disintegrate if subjected tomoisture.

Covers have been tried that incorporate attachment devices such asmagnets and suction cups however, they have had limited success and areunduly complex to produce and use. Another suggested solution is the useof rigid vinyl or hard plastic liners. Such liners are expensive andcomplicated to make and they are bulky to transport to the work site.Another problem is that such hard liners obstruct the subsequentplumbing of the faucets and plug assembly. As a result they are oftenremoved and discarded by trade people. A further problem with rigidliners is their inability to absorb the impact of heavy objects droppedon to the bathing fixture resulting in damage to the underlying sectionof the bathing fixture.

Therefore, what is required is an inexpensive protective cover that doesnot unduly interfere with the ability of the trades people to completetheir tasks, that is tightly fitted to the bathing fixture to stay inplace and to prevent the entry of foreign objects under underneath thecover, and which is strong enough to protect the underlying surface fromunwanted physical contact. It would also be preferable if the protectivecover were water resistant and reusable.

SUMMARY OF THE INVENTION

The present invention is directed to a device and method for protectingbathing fixtures during the construction of a building.

Accordingly, in one aspect of the invention, the invention comprises aliner that is inserted into a bathtub, having an interior surface and adeck, to protect the bathtub during the construction of a building, theliner comprising a unitary pre-molded flexible polymer foam liner formedto match the contours of the interior surface and the deck.

In one aspect of the present invention, the invention comprises a linerthat is inserted into a shower unit to protect the shower unit duringthe construction of a building, the shower unit having an interiorsurface and an upper rim, the liner comprising a unitary pre-moldedflexible polymer foam liner formed to match the contours of the interiorsurface and the upper rim.

In one aspect of the present invention the invention comprises a unitarypre-molded foam liner for a bathing fixture that is pre-molded byspraying liquid foam onto a bathing fixture mold.

In one embodiment, the liner has pre-formed holes to correspond withopenings in the bathing fixture. In one embodiment the polymer ispolyurethane. In another embodiment the polymer is rubber, and in afurther embodiment, the polymer is silicone.

In a further aspect of the invention, the invention comprises a methodof protecting a bathtub having a deck and an interior surface during theconstruction of a building comprising the steps of:

-   -   (a) pre-molding a unitary polymer foam liner by spraying a        polymer foam in liquid form onto a mold of the bathtub and        removing it once the polymer foam solidifies;    -   (b) inserting the polymer foam liner in the bathtub so the deck        and the interior surface are completely covered;    -   (c) cutting holes in the polymer foam liner to correspond with        holes in the interior surface and deck; and    -   (d) removing the polymer foam liner and any debris contained        therein upon completion of the construction.

In a further aspect of the invention, the invention comprises a methodof protecting a shower unit having an interior surface and an upper rimduring the construction of a building comprising the steps of:

-   -   (a) pre-molding a unitary polymer foam liner by spraying a        polymer foam in liquid form onto a mold of the shower unit and        removing it once the foam solidifies;    -   (b) inserting the polymer foam liner in the shower unit so the        upper rim and the interior surface are completely covered;    -   (c) cutting holes in the foam liner to correspond with holes in        the interior surface; and    -   (d) removing the polymer foam liner and any debris contained        therein upon completion of the construction.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of an exemplary embodimentwith reference to the accompanying simplified, diagrammatic,not-to-scale drawings. In the drawings:

FIG. 1 is a diagrammatic depiction of a conventional bathtub.

FIG. 2 is a cross sectional view of a conventional bathtub.

FIG. 3 is a diagrammatic depiction of a conventional shower unit.

FIG. 4 is a cross sectional view of a conventional shower unit.

FIG. 5 is a cross sectional view of a conventional bathtub with oneembodiment of the present invention inserted into it.

FIG. 6 is a cross sectional view of a conventional shower unit with oneembodiment of the present invention inserted into it.

DETAILED DESCRIPTION OF THE INVENTION Scope

The present invention provides for a method and device for protectingbathing fixtures during the construction of a building. When describingthe present invention, all terms not defined herein have their commonart-recognized meanings. To the extent that the following description isof a specific embodiment or a particular use of the invention, it isintended to be illustrative only, and not limiting of the claimedinvention. The following description is intended to cover allalternatives, modifications and equivalents that are included in thespirit and scope of the invention, as defined in the appended claims.

Definitions

In this patent the following words are intended to have the followingmeaning:

-   -   1. “Bathing fixtures” shall collectively refer to bathtubs and        shower units.    -   2. “Foam” shall mean a substance that is formed by trapping many        gas bubbles in a liquid or solid.    -   3. “Polymer” shall mean a naturally occurring or synthetic        compound consisting of large molecules comprising of a linked        series of repeated monomers. Suitable polymers described herein        include polyurethane, rubber and silicone.

All terms not defined herein have their common art-recognized meanings.Description

The present invention is directed to a device and method of protectingbathing fixtures during the construction of a building. FIGS. 1 and 2show a conventional bathtub (12) having a deck (14) and an interiorsurface (20) comprising a floor (18) and a dam (16). The floor (18) hasa drain hole opening (24) and FIGS. 1 and 2 show faucet holes in thedeck (14) and the dam (16) respectively. There is also commonly anoverflow opening (26) as seen in FIG. 2. FIGS. 3 and 4 depict aconventional shower unit (30) having an upper rim (32) and an interiorsurface (38), the interior surface comprising a floor (36) and at leastone wall (34). The floor (36) has an opening for a drain hole (24) and awall may have an opening, or openings (22) for a faucet as shown inFIGS. 3 and 4. It should be understood that the present invention may beused with shower units and bathtubs made from any material includingwith out limitation metal, vinyl and fiberglass. It should be furtherunderstood that the present invention may be used with shower units andbathtubs of any design and shape including those having additionalfeatures such as seats and integral soap ledges.

The protective device is a unitary pre-molded polymer foam liner (40)that is flexible yet strong enough resist tearing and puncture throughthe regular wear that bathing fixtures are subjected to during theconstruction process. The polymer foam is preferably thick enough anddense enough to cushion the blow of impact of any undesired physicalcontact from such things as dropped tiles or tools. The polymer is alsopreferably water resistant. Any suitable polymer may be used. Preferredpolymers include polyurethane, rubber and silicone. It has been found bythe inventor that if polyurethane foam is used, a layer of foam from onequarter to half an inch thick will provide adequate cushioning however,the thickness of the foam may be increased if greater protection isdesired. It has also been determined that polyurethane foam having a sixpounds per cubic foot density rating is a suitable type for use however,the density of the foam can be increased if greater protection isdesired.

The liner (40) is inexpensive and simple to produce. The polymer foam inliquid form is sprayed in a relatively uniform layer onto a mold of thebathing fixture that is to be protected. The mold may be specificallyconstructed, or alternatively, it may simply comprise a bathtub orshower unit of the corresponding model to be protected that has beenmodified to be suitable for use as a mold. The mold may be coated withreleasing agent prior to the application of the polymer foam. Allsurfaces of the bathtub requiring protection are covered with the liquidpolymer foam on the corresponding mold. The polymer foam is applied tothe desired depth. The polymer foam is allowed to dry and solidify andis then peeled as a single piece from the mold. The resultinglight-weight pre-molded polymer foam liner may be rolled or folded tofacilitate transportation and shipping to the user, and ultimately tothe worksite.

As shown in FIGS. 5 and 6, the liner is inserted into the bathtub (12)or shower unit (30) so that all surfaces that require protection arecovered. In the bathtub (12) the liner (40) covers the interior surface(20) and the deck (14). In the shower unit (30) the liner (40) coversthe interior surface (38) and the upper rim (32). As shown in thefigures, the liner may be extended beyond the deck (14) and the upperrim (32) to prevent slippage of the liner (40) within the bathingfixture. As can be seen in FIGS. 5 and 6, by virtue of its shape, thepre-molded liner (40) is in close physical contact with the entireinterior surface of the bathing fixture thereby preventing the entry ofany debris or waste between the liner and the interior surface of thebathing fixture. The pre-molded liner (40) will remain in place evenwhen subjected to external forces such as feet and does not require anyadditional attachment means. The liner (40) is water resistant and canbe reused multiple times. At the completion of the construction process,the liner (40) may be removed form the bathing fixture in the samemanner that a garbage bag is removed from a garbage can, therebyremoving all accumulated debris and waste at once.

The present invention is very easy to modify to create holes that matchthe holes in the bathing fixture for such things as drain holes, faucetsand jets. Holes may be pre-formed in the liner (40) during the moldingprocess. However, although standard designs are used for bathingfixtures, the placement and configuration of the holes in the fixturevaries greatly. The liner (40) of the present invention may be insertedin the bathing fixture without any holes and then when its is time toplumb the fixture in, holes may be cut in the liner very easily using acraft knife or other suitable cutting implement. Alternatively, if themodel of bathing fixture has openings that are consistently placed suchas the drain hole or the overflow opening, then corresponding openingsmay be formed in the liner (40) at the manufacturing stage. Thisbeneficial aspect of the liner (40) means that trades people will not beimpeded in their activities involving the openings in the bathingfixture and thus, the liner will be more likely not to be removed anddiscarded. This is a significant improvement on rigid liners that aredifficult and cumbersome to try modify in such a manner. The presentliner (40) may be modified quickly and efficiently to accommodate themyriad of opening configurations.

The use of the liner (40) will now be described in relation to theprotection of a bathtub, however it will be understood that the methoddescribed would have equal application to a shower unit. The first stepis to obtain a mold of the bathtub that requires protection. Releasingagent is applied to the mold and then liquid polymer foam is applied ina uniform layer to the deck (14) and interior surface (20) to thedesired depth. Any suitable method of application of the polymer foammay be used including spraying. If desired, holes may be preformed inthe liner at this stage to correspond with standard openings in thebathing fixture such as drain holes and overflow openings. The polymerfoam is allowed to dry and the liner is then peeled from the mold.Curing agents as would be used by one skilled in the art may be used topromote the solidification of the liquid polymer foam. The pre-moldedliner (40) is then transported to the worksite and is placed in thebathtub (12) and aligned so that it covers the entire interior surface(20) and the deck (14). A knife can then be used to cut holes in theliner (40) to create holes that are aligned with, and correspond to, theholes in the bathtub (12) such as the faucet holes (22). Upon completionof the construction, the top section of the liner (40) located on thedeck (14) is gathered and the liner (40) is lifted out of the bathtubwith all of the debris and garbage contained within the liner (40). Thepolymer foam is strong enough to support the weight of the debriswithout ripping. The garbage and debris is discarded and the liner maybe cleaned and used for another job.

As will be apparent to those skilled in the art, various modifications,adaptations and variations of the foregoing specific disclosure can bemade without departing from the scope of the invention claimed herein.

1. A liner that is inserted into a bathtub to protect the bathtub duringthe construction of a building, the bathtub having an interior surfaceand a deck, the interior surface having a drain hole opening and anoverflow opening, the liner comprising a unitary pre-molded flexiblepolymer foam liner formed to match the contours of the interior surfaceand the deck of the bathtub.
 2. The liner of claim 1 further comprisingpre-formed holes that correspond with the overflow opening and the drainhole opening.
 3. The liner of claim 1 wherein the polymer is apolyurethane.
 4. The liner of claim 1 wherein the polymer is rubber. 5.The liner of claim 1 wherein the polymer is silicone.
 6. A liner that isinserted into a bathtub to protect the bathtub during the constructionof a building, the bathtub having an interior surface and a deck, theliner comprising a unitary pre-molded flexible polymer foam liner formedto match the contours of the interior surface and the deck, whereby thepolymer foam liner is manufactured by spraying the polymer foam inliquid form onto a bathtub mold and removing it from the mold once thepolymer foam has solidified.
 7. A liner that is inserted into a showerunit to protect the shower unit during the construction of a building,the shower unit having an interior surface and an upper rim, theinterior surface having a drain hole opening, the liner comprising aunitary pre-molded flexible polymer foam liner formed to match thecontours of the interior surface and the upper rim.
 8. The liner ofclaim 7 further comprising a preformed hole to correspond with the drainhole opening.
 9. The liner of claim 7 wherein the polymer ispolyurethane.
 10. The liner of claim 7 wherein the polymer is rubber.11. The liner of claim 7 wherein the polymer is silicone.
 12. A linerthat is inserted into a shower unit to protect the shower unit duringthe construction of a building, the shower unit having an interiorsurface and an upper rim, the liner comprising a unitary pre-moldedflexible polymer foam liner formed to match the contours of the interiorsurface and the upper rim, whereby the polymer foam liner ismanufactured by spraying the polymer foam in liquid form onto a showerunit mold and removing it from the mold once the polymer foam hassolidified
 13. A method of protecting a bathtub having a deck and aninterior surface during the construction of a building comprising thesteps of: (a) pre-molding a unitary polymer foam liner by spraying apolymer foam in liquid form onto a mold of the bathtub and removing itonce the polymer foam solidifies; (b) inserting the polymer foam linerin the bathtub so the deck and the interior surface are completelycovered; (c) cutting holes in the polymer foam liner to correspond withany openings in the interior surface and deck; and (d) removing thepolymer foam liner and any debris contained therein upon completion ofthe construction.
 14. The method of claim 13 wherein the polymer ispolyurethane.
 15. The method of claim 13 wherein the polymer is rubber.16. The method of claim 13 wherein the polymer is silicone.
 17. A methodof protecting a shower unit having an interior surface and an upper rimduring the construction of a building comprising the steps of: (a)pre-molding a unitary polymer foam liner by spraying a polymer foam inliquid form onto a mold of the shower unit and removing it once thepolymer foam solidifies; (b) inserting the polymer foam liner in theshower unit so the upper rim and the interior surface are completelycovered; (c) cutting holes in the foam liner to correspond with holes inthe interior surface; and (d) removing the polymer foam liner and anydebris contained therein upon completion of the construction.
 18. Themethod of claim 17 wherein the polymer is polyurethane.
 19. The methodof claim 17 wherein the polymer is rubber.
 20. The method of claim 17wherein the polymer is silicone.